System / Equipment / Spare Parts Criticality Analysis (SCA)

Dr. Attia Hussien Gomaa Maintenance Engineering Consultant Engineering service - American University in Cairo (AUC)
SCA

2008

Risk / Criticality Parameters : Site/ Train / System / Unit / Equipment: Safety (HSE and security) effect Process effect (production losses) Standby availability (6/5, 5/5, 4/5, 3/5, 2/5)

Costs (operation and maintenance)

Item/ Maintenance / Spare Parts: Mean time to/bet. failure (MTTF or MTBF) Mean time to repair (MTTR) Work order priority Item Cost
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System Criticality Analysis - Dr. Attia Gomaa - 2007

System / Equipment / Spare Part Classification Analysis

Rule 80/20:
Level description Level A B C Critical Medium Non-critical >= 80 15 5 <= 20 30 50 Total Value % Total Item %

Important matrix:
Urgent (due soon) Important Not important Not urgent (not due soon)

A B

B C

Top (10, 5, or 3) items; based on the project size (>= 80% Value)
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System Criticality Analysis - Dr. Attia Gomaa - 2007

ABC Inventory Classification

120 100 80 60 40 20 0 0
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Percentage of Dollars

10

20

30

40

50

60

70

80

90

100
4

Percentage of Items
System Criticality Analysis - Dr. Attia Gomaa - 2007

ABC Classification System

A - Very important B medium important C - least important
High

A B

Annual $ value of items

C
Low
Few Many

Number of Items
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System Criticality Analysis - Dr. Attia Gomaa - 2007

ABC Classification
A - Receive tight control (Continuous Control) Top 10-20% B - Receive relaxed control (Periodic Control) - I Next 30% C- Receive minimal control (Periodic Control)- II Last 50-60%
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System Criticality Analysis - Dr. Attia Gomaa - 2007

Case: Equipment Criticality Systems

System #1: Safety first Level A B Description Major effect on HSE Major effect on Process = High down time cost Example Fire fighting pump Feed crude oil pump

Normal effect on HSE Normal effect on process Without standby Normal effect on HSE Normal effect on process With standby

Water feed pump

Water feed pump

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System Criticality Analysis - Dr. Attia Gomaa - 2007

System #2:
Equipment List HSE Process Standby Level

Gas condensate pump

Feed crude oil pump Export Pump Sump Pit Pump (vessels) Fire fighting pump Water feed pump Instrument Air Compressor Activity list Material list Manpower list
SCA

Major
Medium Major Major Major Normal Major

Major
Major Major Major Minor Medium Major Major

Without
With With With With With With Without

A+
B A A A D A A+

Stand By Generator (Diesel) Major

System Criticality Analysis - Dr. Attia Gomaa - 2007

System #3:
Category Criticality Consequences No potential for injury, pollution, fire or effect on safety systems No effect on safety systems controlling process and no potential for fatalities, moderate or large pollution or fire in classified areas Potential for fatalities, moderate or large pollution and fire in classified areas. No effect on production Brief stop in production < 1 hour or reduced product Production shutdown > 4 hours Insignificant consequential cost < 1,000 USD

1
Safety (HSE)

2 3 1

Production (P)

2 3 1 2 3

Cost ( C )

Moderate consequential cost > 1,000 < 15,000 USD

Substantial consequential cost > 15,000 USD
(2) Medium criticality. (3) High criticality.
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(1) Low criticality.

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Part classification (Rule 80/20)

Part list:
Item Code Unit price ($) Annual Demand (unit)

S11
S12 S13 S14

10
40 100 30

1000
100 10 200

Top 2 Parts

S15 S16 S17

S18 S19 S20

20 200 100
55 80 100

500 600 40
950 30 20

Based on this information, classify & discuss these parts.

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Item Code S16

Unit price ($) 200

Annual Demand (unit) 600

Annual Value $ 120000

Cumulative value $ 120000

Cumulative % 56.7%

Item Level A1

S18
S11 S15 S14 S12

55
10 20 30 40

950
1000 500 200 100

52250
10000 10000 6000 4000

172250
182250 192250 198250 202250

81.4%
86.1% 90.8% 93.7% 95.6%

A2
B1 B2 B3 C1

S17
S19 S20 S13

100
80 100 100

40
30 20 10

4000
2400 2000 1000

206250
208650 210650 211650

97.4%
98.6% 99.5% 100.0%

C2
C3 C4 C5

Total
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211650 13

System Criticality Analysis - Dr. Attia Gomaa - 2007

Failure classification (Rule 80/20)

Turbine Failure list during three years Part Number of MTTR Code failures (hour) P11 2 4 P12 2 15 P13 P14 P15 19 11 2 1 14 21

Top 4 failures

Based on this information, classify & discuss these items.

P16 P17 P18 P19 P20

12 17 10 11 4

12 1 5 12 3
14

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System Criticality Analysis - Dr. Attia Gomaa - 2007

Part Code P14 P16 P19 P18

Number of failures 11 12 11 10

MTTR (hour) 14 12 12 5

Total downtime hours 154 144 132 50

Cum. DT 154 298 430 480

Cum. %

Item Level Level

25.3% 49.0% 70.7% 78.9%

A1 A2 A3 A4

P15
P12 P13 P17

2
2 19 17

21
15 1 1

42
30 19 17

522
552 571 588

85.9%
90.8% 93.9% 96.7%

B1
B2 B3 C1

P20
P11

4
2

3
4

12
8 608

600
608

98.7%
100.0%

C2
C3

Total
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Weight Factor:
Part Code Number of failures 60% 11 12 19 11 17 2 10 MTTR (hour) 40% 14 12 1 12 1 21 5 Value Level

P14 P16 P13 P19 P17 P15 P18

12.2 12.0 11.8 11.4 10.6 9.6 8.0

A1 A2 A3 A4 B1 B2 B3

P12 P20 P11

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2 4 2

15 3 4

7.2 3.6 2.8

C1 C2 C3

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Case:
Part Code Number of failures 2 2 19 11 2 12 MTTR (hour) 4 15 1 14 21 12 HSE effect (1 to 4) 1 2 4 3 2 4 Repair cost (1 to 4) 2 1 4 3 2 4 Delivery type (1 to 3) 1 2 3 2 1 3

P11 P12 P13 P14 P15 P16

P17 P18
P19 P20

17 10
11 4

1 5
12 3

2 1
1 4

3 3
4 1

1 1
3 2

Based on this information, classify & discuss these parts.

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Part Code

(1) HSE effect (1 to 4) 1 2 4 3

(2) Total Downtime (A,B,C) C3 B2 B3 A1

(3) Repair cost (1 to 4) 2 1 4 3

(4) Delivery type (1 to 3) 1 2 3 2

Level

P11 P12 P13 P14

P15
P16 P17 P18 P19 P20
4: Critical

2
4 2 1 1 4
3: Major

B1
A2 C1 A3 A4 C2

2
4 3 3 4 1
2: Medium

1
3 1 1 3 2
1: Minor

Based on this information, classify & discuss these parts.

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Case:
Part Code (1) 50% (2) 25% HSE effect Total (1 to 4) Downtime (A,B,C) 1 2 1 2 (3) 15% Repair cost (1 to 4) 2 1 (4) 10% Delivery type (1 to 3) 1 2

RPN

Level

P11 P12

P13 P14
P15 P16 P17 P18 P19 P20

4 3
2 4 2 1 1 4

2 4
2 4 1 3 3 1

4 3
2 4 3 3 4 1

3 2
1 3 1 1 3 2

Based on this information, classify & discuss these parts.

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Part Code

(1) 50% HSE effect (1 to 4)

(2) 25% Total Downtime (A,B,C)

(3) 15% Repair cost (1 to 4)

(4) 10% Delivery type (1 to 3)

RPN

Level

P16 P13 P14 P20 P19 P15 P12 P17

4 4 3 4 1 2 2 2

4 2 4 1 3 2 2 1

4 4 3 1 4 2 1 3

3 3 2 2 3 1 2 1

3.9 3.4 3.15 2.6 2.15 1.9 1.85 1.8

A1 A2 A3 B1 B2 C1 C2 C3

P18
P11

1
1

3
1
A: Major

3
2
B: Medium

1
1

1.8
1.15
C: Minor

C4
C5

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Risk Level:

Risk = Severity x Probability

Risk = Consequence x Frequency

X
Risk :

Any future bad news (objective or subjective) Severity : Harm or damage caused by a hazard Probability : Likelihood that the harm is realized
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Criticality Assessment : (Risk Matrix) Risk = Severity x Probability

Risk = Consequence x Frequency Probability Severity
(1) Low (1) Low (2) Medium (2 * 1) = 2 (3) High (3 * 1) = 3

(1 * 1) = 1 (1 * 2) = 2
(1 * 3) = 3

(2) Medium
(3) High
SCA

(2 * 2) = 4
(2 * 3) = 6

(3 * 2) = 6
(3 * 3) = 9
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System Criticality Analysis - Dr. Attia Gomaa - 2007

System #1: Power Stations

Probability Or Frequency (1) Low: >2 y (2)Medium: 1-2y (3) High: <1y Consequence or Severity

Risk Matrix
Must be customize to the middle manag. Must be annual updated

(1) Low 1 L 2 L 3 M

(2) Medium 2 L 4 M 6 H

(3) High 3 M 6 H 9 S

S: Serious (10%) H: High (20%) M: Medium (30%) L: Low (40%

For Technical (site) Engineers (Job level):

- Safety Induction - Job Safety Analysis (JSA) - Working At Height SCA
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System #2:
Probability or Frequency (1) Low: Y

Severity
(1) Low 1 N (2) Medium 2 N (3) High 3 N

(2) Medium: 6m-1y

(3) High: <6m

2 N
3 N

4 N
6 C

6 C
9 C

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System #3:

Severity
Probability
>6 f/y 5-6 f/y 3-4 f/y 1-2 f/y <1 f/y

5
H H H M M

4
H H M M M

3
H M M L L

2
M M L L L

1
L L L L L

5 4 3 2 1

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System #4:
RISK ASSESSMENT MATRIX (HSE effect)
Frequency
A Severity People Assets Environment Reputation
Never heard of in EP industry

B
Has occurred in EP industry

E
Happens several times a year in the audited facility

Happens Has occurred in the audited OU several times a year in the audited OU

No injury or damage to health Slight injury or health effects Minor injury or health effects Major injury or health effects

No damage

No effect

No impact

Slight damage

Slight effect

Slight impact

Low Medium

Minor damage Local damage

Minor effect Localised effect

Minor impact Considerable impact

Single fatality Major or permanent damage total disability Multiple fatalities Extensive damage

High
Major effect National impact International impact

Massive effect

Serious
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System Criticality Analysis - Dr. Attia Gomaa - 2007

Risk Matrix
Risk Matrix (Risk probability * consequences) Consequence 1 Catastrophic 2 Critical 3 Moderate 4 Negligible
SCA

I Frequent

II Probable

Probability III IV Occasional Remote

V Improbable

A A A B

A A B C

A B B C

B B C C

B C C C
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System Criticality Analysis - Dr. Attia Gomaa - 2007

System #5:

Risk Assessment Matrix U.S. Army Field Manual 3-100.12.

Probability Severity
Frequent
Catastrophic

Likely

Occasional

Seldom

Unlikely

Critical Marginal
Negligible

E H M

H M L
H High risk L Low risk

H M L

M L L

L L L

E Extremely high risk M Medium risk

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Time Interval between Failures

Consequence
Class Environment Safety Production
1 Small effect No injury No effect

A B C D E T >= 10 Years 5 =< T < 10 2 =< T < 5 0.5 < T < 2 T <= 0.5 Years Years Years Years

2 Minor effect

Minor injury Major injury Single fatality Multiple fatality

Minor effect Less Local effect Medium Major effect High Massive effect

3 Local effect

4 Major effect

5 Massive effect

Ver high

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Level
1

Potential impact
Small effect Minor effect Local effect Major effect

Definition
No disruption to operation, no operational upset or no damage to assets. (total loss value less than US$ xxxxx) Brief disruption, minor operational upset or minor damage to assets. (total loss value less than US$ xxxx) Partial shutdown, moderate operational upset or moderate damage to assets (total loss value less than US$ X Million) Partial operation loss, major operational upset or major damage to assets (total loss value less than US$ xx Million)

Massive effect

Substantial or total loss of operations, damage causing major loss of containment or damage to essential assets (total loss value in excess of US$ xx Million)

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Cat 1

Potential impact Small effect

Definition Small effect Very Local environmental damage. Within the fence and within systems. No change in the environment. Minor effect Contamination. Damage sufficiently large to attack the environment. Single exceedance of statutory or prescribed criterion.. No permanent effect on the environment. Localised effect Limited loss of discharges of known toxicity.

Minor effect

Local effect

Major effect

Major effect Severe environmental damage. The company is required to take extensive measures to restore the contaminated environment to its original state.

Massive effect Massive effect Persistent severe environmental damage or severe nuisance extending over a large area..
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Cat
1

Potential impact
Small injury

Description
Small effect or slight injury or health effects (including first aid case and medical treatment case) - Not affecting work performance Minor injury or health effects (Lost Time Injury) Affecting work performance, such as restriction to activities (Restricted Work Case) or a need to take a few days to fully recover (Lost Workday).. Major injury or health effects (including Permanent Partial Disability) Affecting work performance in the longer term, such as a prolonged absence from work.

Minor injury

Major injury

4
5

Single fatality
Multiple fatality

Single fatality From an accident or occupational illness

Multiple fatalities - From an accident or occupational illness

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Cat A

Time Interval 10 years or more

Description Interval between failures is 10 years or more

B
C D

5 =< T < 10 Years

2 =< T < 5 Years 0.5 < T < 2 Years

Interval between failures is 5 years or more

Interval between failures is 2 years or more Interval between failures is more than 0.5 Years

0.5 year or less

Interval between failures is 0.5 years or less

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